Note: Descriptions are shown in the official language in which they were submitted.
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Improvements in or Relating to Control of Centrifuge
Systems
This invention relates to a method of controlling a
centrifuge system, to a centrifuge system, to a computer
apparatus for use in the system, to a computer-readable
medium, and to a drilling rig comprising the centrifuge
system.
In general, a screw decanter centrifuge has a
cylindrical bowl rotating in one direction and a screw
conveyor disposed concentrically in the bowl and rotating
in the same direction as that of the bowl with a
differential speed. The bowl creates a centrifugal force
to dehydrate a fluid feed mixture. It is rotated at a
constant but variable speed to separate the feed mixture
into a component containing solids (hereinafter called
dehydrated cake) and other components (liquid). As a
result of the centrifugal force created by this rotation,
the solids which are heavier than water are collected on
the inner wall of the bowl. The screw conveyor is rotated
at a relative velocity slightly differentiated from the
velocity of the bowl. This differential speed creates a
relative motion between the series of screw and the bowl
inner wall, which causes the solids to be conveyed slowly
in the direction of the cylinder axis along the bowl
inner wall. The light component or liquid in the feed
mixture is separated from the solids due to the
centrifugal force, and moves toward the inside in the
radial direction. The dehydrated cake which is a
separated heavy material, and the liquid which is a
separated light material, are usually discharged
separately from opposite ends of the bowl.
The differential speed between the screw conveyor
and the bowl can be varied during the operation of the
centrifuge dependent on several parameters and quality of
the feed mixture to be taken out by separation. In actual
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operation these conditions are well known factors.
Accordingly, maintenance of constant revolutions is
generally required for the bowl. On the other hand,
regarding the number of revolutions of the screw
conveyor, there are two systems, the first of which keeps
the number of revolutions of the screw conveyor always
constant in response to that of the bowl, and the second
of which varies the number of revolutions of the screw
conveyor in response to the carrying torque of the screw
conveyor.
Many different industries use decanter centrifuges
in varied applications. They are used in the oil industry
to process drilling mud to separate undesired drilling
solids from the liquid mud. Some decanter centrifuges,
because of their continuous operation, have the advantage
of being less susceptible to plugging by solids. Also,
they may be shut down for long or short periods of time
and then restarted with minimum difficulty, unlike
certain centrifuges which require cleaning to remove
dried solids. Often the solids/liquid mixture is
processed at extraordinarily high feed rates. To
accommodate such feed rates, high torques are
encountered, much energy is required to process the
mixture, and the physical size of the centrifuge can
become enormous.
Various drive systems for creating a differential
speed between the bowl and the screw of a centrifuge are
available. One is a backdrive system for horizontal
centrifuges which uses electric motors and a differential
gear.
When such a centrifuge is used to process drilling
material (drilling fluid with drilled cuttings therein),
changing mud flow conditions often require a human
operator to frequently adjust centrifuge motor speeds to
optimize centrifuge treating performance. Often,
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centrifuges operate a compromise between high performance
and long intervals between maintenance and repair
operations. Problems can occur if the centrifuge's
differential gearbox overheats or is damaged from too-
high gearbox speed differentials. Gearbox damage and
overheating can occur when the backdrive motor is
operated in forward or in reverse. High speed
differential settings can be important for efficient
solids removal from drilling mud which contains an excess
of drilled solids and silt. Both gearbox damage and
centrifuge plugging should be avoided.
Centrifuge manufacturers often specify gearbox
differential speeds that must not be exceeded if safe,
efficient, optimal centrifuge operating life is to be
achieved; but operators frequently do not manually adjust
centrifuge speed differentials optimally, resulting in
reduced centrifuge solids removal and/or shortened
gearbox life. Centrifuge breakdowns due to non-optimal
adjustment and/or operation outside of specified
differential speed parameters in remote areas of oil and
gas prospecting, and offshore, can be costly and cause
expensive delays.
There is a need for a system that makes it easier
for a human operator to adjust and maintain centrifuge
operations at a balance between high performance and
optimized gearbox life. There is a need for a system that
prohibits damage to a centrifuge due to incorrect manual
settings.
The present invention discloses, in certain aspects,
methods for controlling a centrifuge system, the
centrifuge system including: a bowl; a bowl motor system
for rotating the bowl, rotation of the bowl resulting in
a G-force applied to the bowl; a bowl variable frequency
drive for driving the bowl motor; a conveyor rotatable
within the bowl; a conveyor motor for rotating the
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conveyor; a conveyor variable frequency drive for driving
the conveyor motor; a pump for pumping material to be
centrifuged in the bowl; a pump motor for driving the
pump; a pump variable frequency drive for driving the
pump motor; a control system for controlling the bowl
variable frequency drive, the conveyor variable frequency
drive, and the pump variable frequency drive, the control
system including computer apparatus; the computer
apparatus configured to control the centrifuge system in
a G-force differential control mode, the computer
apparatus programmed with a pre-set maximum G-force to be
applied to the bowl; the G-force differential control
mode including controlling the G-force on the bowl as the
bowl is rotated by the bowl motor system driven by the
bowl VFD so that the G-force on the bowl does not exceed
the pre-set maximum G-force; and this controlling of the
G-force accomplished by one of adjusting the G-force on
the bowl and adjusting the speed of the bowl, and
optionally in one aspect, changing on-the-fly from a G-
force mode to a speed mode. The present invention also
discloses a computer readable medium containing
instructions that when executed by a computer implement
such a method for processing material with a centrifuge
system.
In certain aspects the following steps of the method
may be controlled by the computer apparatus of the
control system.
Preferably, the method further comprises the steps
of:
adjusting said G-force from a first G-force to a
second G-force, the adjusting comprising
determining whether application of said second G-
force will increase or decrease a bowl/conveyor-speed
differential and, if the differential will be either
increased beyond a pre-set limit or decreased beyond a
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pre-set limit, preventing application of said second G-
force to said bowl, and
if the bowl/conveyor-speed differential will not
violate pre-set limits, allowing application of said
second G-force to the bowl.
Advantageously, the method further comprises the
steps of:
determining whether said second G-force exceeds said
pre-set maximum G-force or is below a pre-set minimum
and, if so, prohibiting application of said second G-
force to said bowl and, if not, allowing the control
system to proceed to determine if said second G-force can
be applied to the bowl.
Preferably, the method further comprises the steps
of:
calculating a first bowl/conveyor-speed
differential, said first differential corresponding to
the conveyor rotating in a reverse direction, and
calculating a second bowl/conveyor-speed
differential, said second differential corresponding to
the conveyor motor rotating in a forward direction.
Preferably, the method further comprises the step of
providing a display to an operator indicating whether or
not the second G-force will be applied to the bowl.
Advantageously, said controlling of said G-force on
said bowl further comprising the step of inhibiting the
centrifuge from operation in a deadband.
Preferably, the method further comprises the step of
automatically changing direction of said conveyor motor
to inhibit said centrifuge operating in said deadband.
Advantageously, said automatic change in direction
is triggered if a conveyor motor speed is below a preset
minimum.
Preferably, the method further comprises the step of
checking that said pump motor is off before changing
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conveyor motor direction.
Advantageously, the method further comprises the
steps of:
monitoring said conveyor torque during use, and
if said conveyor torque exceeds a preset maximum
conveyor torque by a first pre-set amount for a first
pre-set time period, slowing down the pump motor by a
pre-set amount; and
if the conveyor torque exceeds a preset maximum
conveyor torque by a second pre-set amount for a second
pre-set time period, shutting down said pump motor.
Preferably , the method further comprises the steps
of:
monitoring a bowl torque, and
if said bowl torque exceeds the preset maximum bowl
torque by a first pre-set amount for a first pre-set time
period, slowing down said pump motor by a pre-set amount,
if said bowl torque exceeds a preset maximum bowl
torque by a second pre-set amount for a second pre-set
time period, shutting down said pump motor.
In one embodiment the first pre-set amount is 50%
and the second pre-set amount is 50%
In another embodiment said first pre-set amount is
70% and the second pre-set amount is 80%.
In yet another embodiment said first pre-set amount
is 80% and said second pre-set amount is 90%.
Preferably, the method further comprises the steps
of:
monitoring said pump variable frequency drive for
faults and, if a pump variable frequency drive fault is
detected, stopping said pump motor,
monitoring said conveyor variable frequency drive
for faults and, if a conveyor variable frequency drive
fault is detected, stopping said bowl and stopping said
conveyor, and
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monitoring said bowl variable frequency drive for
faults and, if a bowl variable frequency drive is
detected, stopping said bowl and stopping said conveyor.
Advantageously, the method further comprises the
step of ensuring that said bowl and said conveyor are
rotating at a desired speed before activating said pump
motor to supply fluid to the centrifuge for separation.
Preferably, the method further comprises the steps
of:
storing in said computer apparatus a pre-set minimum
speed for said bowl and an maximum speed for said
conveyor,
activating said pump motor if
a bowl speed is above a pre-set minimum speed for
said bowl,
a conveyor speed is above the pre-set speed for said
conveyor, and
a conveyor torque is less than or equal to an amount
of a pre-set maximum conveyor torque.
Advantageously the method further comprises the
steps of:
stopping said pump, and
ensuring a bowl torque and a conveyor torque are
below pre-set levels before stopping rotation thereof.
Advantageously, initially said conveyor motor is
running in a first direction, the method further
comprising the step of changing said conveyor motor to
run in a second direction opposite to the first
direction.
Preferably, the method further comprises the step of
said computer apparatus switching on-the-fly between
controlling the G-force by adjusting the G-force on the
bowl and controlling the G-force by adjusting the speed
of the bowl.
Preferably, initially a first G-force is applied to
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solids laden fluid within the bowl, the method further
comprising the step of changing the force applied to the
material within the bowl to a second force different from
the first G-force.
Advantageously, said changing of said G-force is
done on-the-fly.
Preferably, the method further comprises the step of
running the centrifuge system in an idle mode.
In certain aspects the method comprises selecting
using the control system a specific model centrifuge to
be controlled by the control system.
Advantageously said centrifuge system further
comprises
network communications apparatus for providing
communication between at least one of the variable
frequency drive apparatuses and a site remote from a
location of the centrifuge system, and
the network communications apparatus for
communicating with a computer system at the location of
the centrifuge system for controlling at least one of the
variable frequency drive apparatuses,
the method further comprising the step of
communicating via the network communications apparatus
with the computer system to control the centrifuge
system.
Preferably, the centrifuge system further comprises
a load sensor apparatus for sensing load of said bowl
motor and of said conveyor motor and for producing load
signals indicative of said loads and pump controller
apparatus for receiving said load signals and for
controlling said pump in response thereto, the method
further comprising the step of controlling said pump in
response to said load signals.
Advantageously, said pump controller shuts down the
pump in response to load signals indicating the
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centrifuge system is jammed with material, thereby
stopping flow of material to the bowl.
In some embodiments said solids-laden fluid
comprises drilling fluid and drilled cuttings to be
separated by the centrifuge system.
According to another aspect of the present invention
there is provided a centrifuge system comprising the
centrifuge system features as set out above.
According to another aspect of the present invention
there is provided for use in a centrifuge system as set
out above, a computer apparatus adapted to perform the
computer apparatus steps described above.
According to yet another aspect of the present
invention there is provided a computer readable medium
storing computer executable instructions that when
executed cause a computer apparatus to perform the
computer apparatus steps described above.
According to another aspect of the present invention
there is provided a drilling rig comprising a centrifuge
system as described above.
Preferably the drilling rig further comprises:
sensor apparatus connected to the centrifuge system
for sensing a parameter indicative of operation of the
centrifuge system for providing a signal corresponding to
said parameter,
control apparatus for receiving signals from the
sensor apparatus for controlling the centrifuge system
based on said signals,
the control apparatus for monitoring and analyzing a
plurality of signals from the sensor apparatus and for
transmitting signals indicative of information related to
operation of the centrifuge system to a remote computer
apparatus on said drilling rig, the remote computer
apparatus for processing a set of health check rules for
health checks comprising logical rules, inputs and
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outputs for defining events associated with the status of
the centrifuge system,
the remote computer apparatus for determining a
severity code for each event and for reporting the events
and severity codes to a central server, the events
reported by the remote computer apparatus to the central
server in a protocol defining a data structure, the data
structure comprising a hierarchical tree node structure
wherein results from application of the health check
rules are a bottommost node of the tree node structure.
Advantageously said remote computer apparatus is
adapted to provide to the central server the results as
records containing node information regarding an
appropriate location for the results in a tree node
structure.
Preferably said control apparatus is adapted to run
the health checks in real time to provide results
regarding on-going status of the centrifuge system to
indicate a potential failure of the centrifuge system.
Advantageously said control apparatus is adapted to
provide information regarding centrifuge system operation
so that maintenance can be performed on the centrifuge
system without shutting down drilling by said drilling
rig.
Preferably, the drilling rig further comprises
recording apparatus in communication with at least one
on-board controller for at least one of the variable
frequency drive apparatuses for recording personnel
operator inputs thereto, wherein said recording apparatus
is adapted to produce a record identifying each personnel
operator's inputs.
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For a better understanding of the present invention
reference will now be made to the accompanying drawings,
in which:
Fig. 1 is a sectional view of a prior art centrifuge
which is controlled by systems and methods according to
the present invention;
Fig. 2 is a schematic view of the centrifuge of Fig.
1 along with a control system apparatus according to the
present invention;
Fig. 2A is a schematic view of a system according to
the present invention;
Fig. 3 is a schematic view of a system according to
the present invention;
Fig. 4 is a schematic view of a computer method
according to the present invention;
Fig. 5 is a schematic view of a computer method
according to the present invention;
Fig. 6 is a schematic view of a computer method
according to the present invention;
Fig. 7 is a schematic view of a computer method
according to the present invention;
Fig. 8 is a side view of a system according to the
present invention;
Fig. 9 is a top view of a system according to the
present invention;
Fig. 10 is an illustration of a preferred status
display for an oil recovery system showing status for
individual rigs and aggregated worse-case status for
geographical areas;
Fig. 11 is an illustration of a preferred status
display for an oil recovery system showing status for
individual rigs and aggregated worse-case status for a
smaller geographical area including Western Canada;
Fig. 12 is an illustration of a preferred status
display for an oil recovery system showing status for
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individual rigs and panel results showing text
descriptions and color-coded status for a single oil rig;
Fig. 13A is an illustration of a preferred status
display for an oil recovery system and a sub status for
an individual rig;
Fig. 13B is an illustration of an alternative status
display for an oil recovery system and a sub status for
an individual rig;
Fig. 14 is an illustration of a preferred status
display for an oil recovery system and a lower level sub
status for an individual rig;
Fig. 15 is an illustration of a preferred status
display for an oil recovery system and a lower level sub
status for an individual rig;
Fig. 16 is an alternative tabular status display for
an oil recovery system;
Fig. 17 is an alternative tabular status display for
an oil recovery system;
Fig. 18 is an illustration of a preferred health
check system reporting health checks from an oil rig to a
user via satellite;
Fig. 19 is an illustration of a preferred health
check system reporting health checks from an oil rig to a
user via satellite;
Fig. 20 is an illustration of a preferred protocol
which defines an event reporting data structure for data
base population and display;
Fig. 21A is a front view of a control system for
centrifuge operation according to the present invention;
Fig. 21B is a side view of the system of Fig. 21A;
Fig. 22 is a front view of a control system for
centrifuge operation according to the present invention;
Fig. 23 is a schematic view of components of the
system of Fig. 21A;
Fig. 24 is a schematic view of a method according to
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the present invention useful for centrifuge control;
Fig. 25 is a schematic view in a method according to
the present invention useful for centrifuge control;
Fig. 26 is a schematic view in a method according to
the present invention useful for centrifuge control;
Fig. 26A is a schematic view in a method according
to the present invention useful for centrifuge control;
Fig. 27 is a schematic view in a method according to
the present invention useful for centrifuge control;
Fig. 28 is a schematic view in a method according to
the present invention useful for centrifuge control;
Fig. 28A is a schematic view in a method according
to the present invention useful for centrifuge control;
Fig. 28B is a schematic view in a method according
to the present invention useful for centrifuge control;
Fig. 28C is a schematic view in a method according
to the present invention useful for centrifuge control;
Fig. 28D is a schematic view in a method according
to the present invention useful for centrifuge control;
Fig. 28E is a schematic view in a method according
to the present invention useful for centrifuge control;
Fig. 28F is a schematic view in a method according
to the present invention useful for centrifuge control;
Fig. 28G is a schematic view in a method according
to the present invention useful for centrifuge control;
Fig. 28H is a schematic view in a method according
to the present invention useful for centrifuge control;
Fig. 29A is a schematic view in a method according
to the present invention useful for centrifuge control;
Fig. 29B is a schematic view in a method according
to the present invention useful for centrifuge control;
Fig. 29C is a schematic view in a method according
to the present invention useful for centrifuge control;
Fig. 30A is a view of a touch screen apparatus of a
control system according to the present invention
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regarding language selection for communication between an
operator and the control system;
Fig. 30B is a view of a touch screen apparatus of
the control system of Fig. 30A regarding password input
to access the system;
Fig. 30C is a view of a touch screen apparatus of
the control system of Fig. 30A regarding correct clock
setting;
Fig. 30D is a view of a touch screen apparatus of
the control system of Fig. 30A regarding settling the
system clock;
Fig. 30E is a view of a touch screen apparatus of
the control system of Fig. 30A regarding proceeding with
pre-set operational parameters or proceeding with new
parameters;
Fig. 30F is a view of a touch screen apparatus ;
Fig. 31 is a view of a touch screen apparatus of the
control system of Fig. 30A showing a Main Menu for
controlling the system;
Fig. 31A is a view of a touch screen apparatus of
the control system regarding selecting a particular make
and model centrifuge to be controlled whose parameters
are already pre-programmed into the control system;
Fig. 31B is a view of a touch screen apparatus of
the control system regarding certain specific centrifuges
which can be controlled and shoe operational parameters
are already in the system;
Fig. 31C is a view of a touch screen apparatus of
the control system regarding selecting a type of pump in
the centrifuge system to be controlled;
Fig. 31D is a view of a touch screen apparatus of
the control system regarding selection of a specific
pump;
Fig. 31E is a view of a touch screen apparatus of
the control system regarding selection of a particular
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type of task to be accomplished by the controlled
centrifuge system or an "idle" operation mode;
Fig. 31F is a view of a touch screen apparatus of
the control system regarding selection of system idle
mode;
Fig. 31G is a view of a touch screen apparatus;
Fig. 32 is a view of a touch screen apparatus of the
control system regarding selection of a method for
controlling the centrifuge;
Fig. 33A is a view of a touch screen apparatus of
the control system regarding verification of particular
selections;
Fig. 33B is a view of a touch screen apparatus of
the control system;
Fig. 34 is a view of a touch screen apparatus of the
control system regarding selection of data to display
regarding system operation;
Fig. 35 is a view of a touch screen apparatus of the
control system regarding graphical display of certain
data about system operation;
Fig. 36A is a view of a touch screen apparatus of
the control system regarding centrifuge operation,
status, and control with the system in a Dewatering
Clarification Mode;
Fig. 36B is a view of a touch screen apparatus of
the control system regarding selectively controlling the
centrifuge system by adjusting the G-force, as G-force,
on a bowl of the system;
Fig. 36C is a view of a touch screen apparatus of
the control system regarding selectively controlling the
centrifuge system by adjusting a system speed
differential;
Fig. 36D is a view of a touch screen apparatus of
the control system regarding adjusting speed of a system
pump motor;
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Fig. 36E is a view of a touch screen apparatus of
the control system regarding system operation in a
Dewatering Clarification Mode, presenting the option for
changing direction of a system conveyor motor;
Fig. 37 is a view of a touch screen apparatus of the
control system;
Fig. 37A is a view of a touch screen apparatus;
Fig. 38 is a view of a touch screen apparatus of the
control system;
Fig. 39 is a view of a touch screen apparatus of the
control system regarding maintenance status of various
system parts;
Fig. 40 is a view of a touch screen apparatus of the
control system regarding system shut down;
Fig. 41 is a view of a touch screen apparatus of the
control system;
Fig. 42 is a view of a touch screen apparatus of the
control system regarding the status of any system alarms;
and
Fig. 43 is a view of a touch screen apparatus of the
control system regarding loss of communication between
the control system and the centrifuge system.
As shown in Figs. 1 and 2, a centrifuge system 10
according to the present invention has a bowl 12,
supported for rotation about its longitudinal axis, has
two open ends 12a and 12b, with the open end 12a
receiving a drive flange 14 which is connected to a drive
shaft for rotating the bowl. The drive flange 14 has a
longitudinal passage which receives a feed tube 16 for
introducing a feed slurry, e.g. drilling material, into
the interior of the bowl 12. A screw conveyor 18 extends
within the bowl 12 in a coaxial relationship thereto and
is supported for rotation within the bowl. A hollow
flanged shaft 19 is disposed in the end 12b of the bowl
and receives a drive shaft 20 of an external planetary
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gear box for rotating the screw conveyor 18 in the same
direction as the bowl at a selected speed.
The wall of the conveyor 18 has one or more openings
18a near the outlet end of the tube 16 so that the
centrifugal forces generated by the rotating bowl 12 move
the slurry radially outwardly and pass through the
openings 18a and into the annular space between the
conveyor and the bowl 12. The liquid portion of the
slurry is displaced to the end 12b of the bowl 12 while
entrained solid particles in the slurry settle towards
the inner surface of the bowl due to the G forces
generated, and are scraped and displaced by the screw
conveyor 18 back towards the end 12a of the bowl for
discharge through a plurality of discharge ports 12c
formed through the wall of the bowl 12 near its end 12a.
Weirs 19a (two of which are shown) are provided
through the flanged portion of the shaft 19 for
discharging the separated liquid. The centrifuge as shown
in Fig. 1 is known in the prior art and is enclosed in a
housing or casing (not shown) in a conventional manner.
As shown in Fig. 2, a drive shaft 21 forms an
extension of, or is connected to, the drive flange 14 and
is supported by a bearing 22. A variable speed AC main
drive motor 24 has an output shaft 24a which is connected
to the drive shaft 21 by a drive belt 26 and therefore
rotates the bowl 12 of the centrifuge at a predetermined
operational speed. The flanged shaft 19 extends from the
interior of the conveyor 18 to a planetary gear box 32
and is supported by a bearing 33. A variable speed AC
back drive motor 34 has an output shaft 34a which is
connected to a sun wheel 35 by a drive belt 36 and the
sun wheel is connected to the input of the gear box 32.
The motor 34 rotates the screw conveyor 18 of the
centrifuge through the planetary gear box 32 which
functions to establish a differential speed of the
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conveyor 18 with respect to the bowl 12. A coupling 38 is
provided on the shaft of the sun wheel 35, and a limit
switch 38a is connected to the coupling which functions
in a conventional manner to shut off the centrifuge when
excessive torque is applied to the gearbox 32.
For receiving and containing the feed slurry being
processed, there is a tank 40 and a conduit 42 connected
to an outlet opening formed in the lower portion of the
tank to the feed tube 16. An internal passage through the
shaft 21 receives the conduit 42 and enables the feed
slurry to pass through the conduit and the feed tube 16
and into the conveyor 18.
The slurry is pumped from the tank 40 by a variable
frequency drive pump 44 which is connected to the conduit
42 and is driven by a drive unit 46, e.g. an electric
motor, which pumps the slurry through the conduit 42 and
the feed tube 16, and into the centrifuge. A control
valve 52 disposed in the conduit 50 controls flow in the
conduit. Two variable frequency ("VFD") drives 54 and 56
are respectively connected to the motors 24 and 34 for
driving the motors at variable frequencies and at
variable voltages. The VFD 54 is also electrically
connected to the input of a magnetic starter 58, the
output of which is connected to the drive unit 46. The
VFD 54 supplies a control signal to the starter 58 for
starting and stopping the drive unit 46, and therefore
the pump 44. The drive unit 46 may also be a variable
frequency drive.
A control system 60 is provided which contains
computer programs stored on computer readable media and
containing instructions for controlling the operation of
the centrifuge and the pump 44. To this end, the control
system 60 has several input terminals two of which are
respectively connected to the VFDs 54 and 56 for
receiving data from the VFDs, and two output terminals
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for respectively sending control signals to the VFDs. The
control system 60 thus responds to the input signals
received and controls the VFDs 54 and 56 in a manner so
that the drive units can continuously control the system
and vary the frequency and the voltage applied to the
respective AC motors 24 and 34, to continuously vary the
rotation and the torque applied to the drive shaft 21 and
to the sun wheel 35, respectively.
The control system 60 has another input terminal
connected to the drive unit 46 with a motor 46a for
receiving data from the drive unit 46. Another output
terminal of the control system 60 is connected to the
drive unit 46 for sending control signals to the drive
unit 46. The control system 60 thus responds to the input
signals received from at least one the VFDs 54 and 56 and
can send corresponding signals to the drive unit 46 to
for varying the operation of the pump 44. Another input
terminal of the control system 60 is connected to the
limit switch 38a which provides a signal in response to
excessive torque being applied to the gear box 32.
Mounted on the outer surface of the bowl 12 is a
vibration detector 62 which is connected to the control
system 60, and responds to excessive vibrations of the
centrifuge for generating an output signal that causes
the control system to send signals to the VFDs 54 and 56
to turn off the motors 24 and 34, respectively and
therefore shut down the centrifuge.
Near the bearings 22 and 33 are connected a pair of
accelerometer sets 64a and 64b, each set including two
accelerometers for respectively measuring certain
operational characteristics of the drive shafts 21 and 20
and their associated bearings. The accelerometer sets 64a
and 64b are connected to the control system 60 for
passing their respective output signals to the control
system 60 for processing. The accelerometer sets 64a and
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64b can be of the type disclosed in U.S. Patent No.
4,626,754.
Each accelerometer set includes two or more
accelerometers having orthogonal axes that are placed on
the frames of the bearings 22 and 33 for detecting
vibrations caused by the rotating bowl 12 and screw
conveyor 18, as well as the drive shaft 21 and the sun
wheel 35. The signals provided by the accelerometers of
each set 64a and 64b are passed to the control system 60
where a computer program contained therein analyzes the
signals for the presence of specific predetermined
frequency signatures corresponding to particular
components and their status, which could include a
potentially malfunctioning condition. The computer
program is designed to provide instructions to produce an
output in response to any of these frequency signatures
being detected. The back current to the drive units 24
and 34, are proportional to the loading of the bowl 12
and the conveyor, respectively, the values of which is
fed back to the control system 60.
The control system 60 has conventional devices
including, but not limited to, programmable media,
computer(s), processor(s), memory, mass storage
device (s), video display (s), input device (s), audible
signal (s), and/or programmable logic controller(s).
Optionally, e.g. in -field applications, a generator is
provided which generates electrical power and passes it
to a breaker box which distributes the power to the VFDs
54, 56, and 46. Optionally, the VFD 54 (and any VFD of
the system 10 and any VFD disclosed herein) can have a
manual potentiometer apparatus 54a for manually
controlling a motor; a torque display apparatus 54b; an
rpm/speed display apparatus 54c; and/or an EMI apparatus
(human-machine interface, e.g. a touch screen system) 54d
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which provides a visual display of the system operation
and a tactile means of control.
In one method according to the present invention,
the storage tank 40 receives the slurry, (which, in one
particular aspect, is a mixture of drilling fluid and
drilled cuttings). The control system 60 sends an
appropriate signal, via the VFD 54, to the starter 58
which functions to start the VFD 46 and activate the pump
44. The slurry is pumped through the conduit 42 and into
the interior of the bowl 12 under the control of the
control system 60. The motor 24 is activated and
controlled by the VFD 54 to rotate the drive shaft 21,
and therefore the bowl 12, at a predetermined speed. The
motor 34 is also activated and driven by the VFD 56 to
rotate the sun wheel 35, and therefore the screw conveyor
18, through the planetary gear box 32, in the same
direction as the bowl 12 and at a different speed. As a
result of the rotation of the bowl 12, the centrifugal
force thus produced forces the slurry radially outwardly
so that it passes through the openings 18a in the
conveyor and into the annular space between the conveyor
and the bowl 12. The drilling fluid portion of the slurry
is displaced to the end 12b of the bowl 12 for discharge
from the weirs 19a in the flanged shaft 19. The entrained
solid particles (drilled cuttings) in the slurry settle
towards the inner surface of the bowl 12 due to the G
forces generated, and are scraped and displaced by the
screw conveyor 18 back towards the end 12a of the bowl
for discharge through the discharge ports 12c.
The control system 60 receives signals from the VFD
46 corresponding to the pumping rate of the pump 44, and
signals from the VFDs 54 and 56 corresponding to torque
and speed of the motors 24 and 34, respectively. The
control system 60 contains instructions which enables it
to process the above data and control the VFDs. The
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control system 60 controls the VFDs 54 and 56 to vary the
frequency and voltage applied to the motors 24 and 34, as
needed to control and/or continuously vary the rotational
speed of, and the torque applied to, the drive shaft 21
and the sun wheel 35, to maintain predetermined optimum
operating conditions. The control system 60 also monitors
the torque applied to the sun wheel 35 from data received
from the VFD 56 and maintains the torque at a desired
level. In the event one of the inputs to the control
system 60 changes, the system contains instructions to
enable it to change one or more of its output signals to
the VFDs 54 and 56 and/or the VFD 46, to change their
operation accordingly. The accelerometer sets 64a and 64b
respond to changes in rotational speed of the drive shaft
21 and the sun wheel 35, and therefore the bowl 12 and
the conveyor 18, in terms of frequency, as well as
changes in the drive current to the motors 24 and 34 in
terms of amplitude which corresponds to load, and
generate audible beats corresponding to frequency changes
that occur as the loading on the bowl and the conveyor
change. These audible beats are processed by the control
system 60 and enable the predetermined optimum operating
conditions to be attained. In the event the centrifuge
becomes jammed for whatever reason the control system 60
will receive corresponding input signals from the VFDs 54
and/or 56 and will send a signal to the starter 58 to
turn off the pump 44 and thus cease the flow of the feed
slurry to the centrifuge.
Figs. 4 - 7 illustrate one method according to the
present invention for automatically controlling the speed
of the motor 34, the speed of the motor 24, and the
differential between these speeds. In one aspect, each
VFD has its own on-board controller with programmable
media, e.g. a programmable logic controller ("PLC"), 54p,
56p, 46p, respectively, for controlling the VFDs and for
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communicating with all the system's apparatuses and
devices (as indicated, e.g., by the dash-dot lines to
each PLC). Any VFD can initiate any command for any
apparatus or device and each VFD can communicate with the
other VFD's. In one particular aspect as shown in Fig. 1,
the control system 60 is deleted. Figs. 4 - 7 show a
program for programming the PLCs 54p, 56p, and 46p which,
in certain aspects, can all intercommunicate and which,
in certain aspects, have programmable media programmable
to recognize and operate a certain size and type of
motor, to perform a certain task or tasks, and/or to
communicate wit other items or apparatuses.
Alternatively, programmable media PM in the control
system is programmed in this way. Optionally, in any
system herein the tank 40 (and any known container, tank,
reservoir or cuttings box) can have an agitator system 70
according to the present invention which includes an
agitator 71 with a housing 76 and with a blade or blades
72 on a rotatable shaft 75 for agitating material and a
VFD variable frequency drive 73 for controlling the
system 70 (and/or the system 70 can be controlled by the
system 60). Optionally, the VFD 73 may have its own on-
board programmable logic controller 74. In one aspect,
the control system 60 and/or one, two, or three, of the
on-board controllers (e.g. one or more of the on-board
PLCs) includes recording media for recording inputs made
by personnel so that a record is provided of personnel
efforts to control the centrifuge system and/or to change
its operating parameters. In one particular aspect such a
record is provided which identifies each individual
operator.
As shown in Fig. 3 a system SY according to the
present invention has a centrifuge CE (or centrifuges) on
site at a rig with motors and VFD's as in the systems of
Fig. 2 or 2A or any system according to the present
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invention. The VFD has network communications apparatus
NE which provides communication via a system such as the
Internet I between the VFD and personnel and/or apparatus
at a remote site RS for remote control of the VFD and
thus of the centrifuge CE. Remote programming and
reprogramming of programmable media associated with the
VFD is possible according to the present invention. The
apparatus NE also, in one aspect, provides communication
between the VFD and an on-site computer system CP (e.g.
laptop, desktop) with either a wired or wireless
connection so that personnel on-site can control the VFD
and, with a VFD that has associated programmable media
(e.g., but not limited to, a PLC) program and reprogram
the programmable media.
As shown in Fig. 4, the program decides whether a
manual setting (Block 101) of the speed of the motor 34
is acceptable or whether the manual setting (set by
operator personnel) is to be automatically overridden.
Block 107 receives inputs from Block 101 which indicates
the speed of the motor 34 which has been manually set and
inputs from Blocks 127 and 109 which indicate whether a
maximum or minimum speed differential (differential
between speeds of motors 34 and 24) has been exceeded. If
the speed differential based on the manually set speed
for motor 34 (Block 101) is within the pre-set limits,
the system is allowed to proceed in operation with the
manually set speed. If the speed differential for the
manually set speed exceeds either the maximum or the
minimum limit, then the PLCs 56p take over and
automatically override the manually set speed for the
motor 34. In the event that the system does automatically
override the operator, a limit indicator (Block 110) is
activated to tell the operator that the operator is no
longer in control of the system.
The program, when operating in automatic override
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mode, produces from Block 107 a signal indicative of
actual allowable bowl speed communicated to Block 108.
Block 108 provides a signal to the VFD 56p which is
indicative of the frequency of power the VFD is to
provide to the motor 34 to drive the motor 34 at a
selected speed so that a desired speed differential
between the motor 34 and the motor 24 is achieved.
Program Block 111 provides a signal to the Block 108
which is an allowable minimum speed differential and this
prevents the communication of speed differential from the
Block 107 which is to high or too low.
Block 102 indicates to Block 127 whether the motor
34 is running in forward or reverse. This is important
because there are different limits on allowable speeds
for different motor directions. When the motor 34 is
running forward (e.g. for processing relatively clean
fluid), the minimum speed differential reference (Block
18) is the bowl speed (Block 116) minus an entered
minimum differential reference (Block 117), a value that
prevents sudden centrifuge clogging. Block 118
communicates to Block 127 a percentage of actual
allowable bowl speed minus a pre-set minimum percentage.
Block 111 converts the value from Block 116 to an
absolute (always positive) value.
When the motor 34 is running in reverse (e.g. for
processing slurries with a relatively high solids level)
the maximum speed differential is calculated to produce
an allowable maximum speed differential which is fed to
Block 127. The 100% reference speed (allowable speed) of
Block 104 the minuend of Block 126 (the fastest speed at
which the bowl can operate) and the subtrahend is from
Block 103 (actual bowl speed). The resulting remainder
signal produced by Block 126 indicates the allowable
maximum speed differential and becomes the motor 34 speed
reference for Block 127 whenever an excessive speed
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differential is detected by Block 109 while the motor 34
is running in reverse. Block 110 turns on a status lamp
which indicates that the program is limiting the speed
reference for the motor 34, reducing the speed
differential, and overriding the operator's setting.
Blocks 105 and 106 indicate whether the operator's
manual setting is acceptable. If not, i.e. if the maximum
speed differential is exceeded by the operator's setting
(Block 105) or if the minimum speed differential is
exceeded by the operator's setting (Block 106), Block 109
is told to regard this and an appropriate signal is
communicated to Blocks 107 and 110. In certain preferred
embodiments the scroll or conveyor speed is maintained
slower than the bowl speed and this is accomplished with
a system as shown, e.g., in Fig. 4. With such a system
the scroll or conveyor speed is automatically prevented
from equalling or exceeding the bowl speed. In one
aspect, such a system enhances gear box life.
Fig. 5 illustrates the detection of the desired
minimum speed differential between the speeds of the
motors 34 and 24. An operator manual sets a minimum speed
differential (Block 204). Block 209 indicates whether the
system is running in reverse (i.e., not forward). Block
208 indicates whether the system is actually running. If
the system is running, and is running in reverse, Block
206 is "true" and this "true" indication is stored in
Block 13 which is read by Block 212. Block 212 indicates
that a minimum speed differential is enabled.
Block 207 receives the indication from Block 212
that the minimum speed differential is enabled (and also
the value for this differential) and, from Block 205,
whether the actual (in real time) speed differential
(from Block 203) is less than 10% of what was set in
Block 204. If the indication from Block 205 is that the
actual speed differential is less than 10% of what the
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operator set, and Block 212 indicates that the minimum
speed differential is enabled, then Block 207 sends a
signal to Block 211 that the system must override the
manual setting and control the speed differential. The
indication of Block 211 is used by Block 106, Fig. 4
("W2" indicates write number to memory; "R2"' indicates
read number from memory). This causes the programmed
logic (Fig. 4) to switch the speed reference source from
Block 101 to Block 127 and Block 107 selects Block 127.
Fig. 6 illustrates programming for detection of
whether the automatic maximum speed differential is on.
In Block 303 the actual (in real time) speed of the motor
34 (Block 301) is added to the actual speed of the motor
24. The resulting sum is compared (in Block 305) with a
pre-set maximum speed differential (from Block 304). If
the comparison indicates that the actual speed
differential exceeds the maximum speed differential,
Block 305 communicates this to Block 306 and that the
maximum speed differential function is "on." This
indication is used by Block 105, Fig. 4.
Fig. 7 provides an indication that the system is in
protective mode (e.g. when the system overrides manual
personnel inputs). In this mode an operator cannot do
what he is attempting to make the system do and,
optionally, the system can provide an alarm at remote
site regarding such an operator attempt and/or that the
system is in protection mode. Block 402 provides an
indication that the drive is (or is not) in reverse mode.
Block 401 indicates whether the system is within a
desired minimum speed differential between conveyor and
bowl. Block 403 provides a signal indicative of the
situation in which the drive is not in reverse and the
system is not within the minimum speed differential.
Block 404 acts on the signal from Block 403 and places
the system in protection mode.
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Fig. 8 shows an embodiment of a system 70 as in Fig.
2 and like numerals indicate like parts. A drive motor 77
drives a shaft 78 which is coupled with a coupling or
gear mechanism 79 which, in turn drives the drive shaft
75 and the blade (or blades) 72. A stuffing box 81 or
other suitable seal apparatus seals the shaft exit point
from the housing 76. A moisture sensor 82 in
communication with the VFD 73 and/or the PLC 74 senses
the moisture level within the housing 76 and conveys a
measurement of this level to the VFD 73 and/or PLC 74.
Sensors 83, 84, and 85 sense motor speed and shaft speeds
and/or current usage, and convey this information to the
VFD 73 and/or PLC 74. The VFD itself can provide current
and speed measurements.
As shown in Fig. 9, a tank etc. according to the
present invention may have two, three, four, five (as
shown) or more agitator systems 70 according to the
present invention each with its own corresponding VFD 73
and/or PLC 74.
In many prior art systems, an agitator is simply an
on/off apparatus which, when it fails, is removed and
replaced without any monitoring of its operation until
failure. Several things cause agitator failure, e.g. lack
of lubrication; and several things inhibit efficient
agitator operation, e.g. injury to or loss of an
agitating blade.
With a system according to the present invention
various sensed parameters and measurements provide an
indication of agitator wear, injury, and/or failure. If a
gear mechanism or motor requires an increase in current
(which can be sensed by the sensors in these items and/or
by a VFD), this can indicate a lack of proper
lubrication. This problem can be sensed, alarmed and/or
displayed, (e.g. on an on-site or remote display 88) and
then remedied prior to agitator failure. Optionally, the
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VFD can stop the motor so that proper lubrication can be
achieved. Optionally, the system can shut down other
agitators in the same tank, etc. until the problem is
dealt with.
If the system measures a decrease in current to an
agitator, this can indicate a damaged or lost blade. The
system can provide an alarm and/or display of the
situation and/or shut the agitator down until the blade
is repaired or replaced (and shut down other agitators
until such repair or replacement).
Initially with an agitator or agitators in good
working condition the system can measure average current
to the agitator or agitators and, during future
operation, if a deviation from these averages is sensed,
the system can determine the agitator or agitator with
the deviation and whether it is deviant due to an
increase in current or a decrease in current - each of
which can indicate particular problems. With separate
VFD's for each of a plurality of agitators in a tank,
different agitators can be run at different speeds. When
moisture is sensed within an agitator housing, this can
indicate a break in the housing or a failure of the shaft
stuffing box or seal. As with the response to any sensed
parameter, in response to failure or a condition that can
lead to failure, the system can shut down the agitator
and/or provide an alarm either on-site or remote. Prior
to agitator failure, the system can provide a warning
and/or indicate scheduled maintenance and/or preventive
maintenance is needed before an agitator actually fails.
The display 88 can be used to monitor the
agitator(s) in real time. Any suitable recording
apparatus 89 (in certain aspects in a VFD or in a PLC)
can record all sensed data and can provide access to the
data. A heat sensor 87 interacts with the VFD and/or PLC
as does the sensor 82. Optionally, all sensors are in
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communication with a control system like the control
system 60 described above.
In certain embodiments, (see, e.g. Figs. 10 - 19)
systems according to the present invention provide tests,
checks, and intelligent diagnostics specific to oil rig
operational scenarios, to vibratory separator operation
and, in particular aspects, to centrifuge operational
scenarios which enhance oil rig safety and efficiency of
oil field drilling operations, in certain particular
aspects when applied to an automatically operated
centrifuge with an electronic and/or computerized control
system to ensure continuous and proper system operation
and availability during downhole operations. In certain
systems according to the present invention failures,
performance degradation and/or predicted failures are
reported to service personnel that perform additional
diagnostics or dispatch field personnel to replace or
repair the systems as necessary.
The present invention provides a method and
apparatus for remotely monitoring, analyzing and
affirmatively notifying appropriate personnel of problems
and events associated with an oil recovery system
comprising one or more, e.g. hundreds, of oil rigs over a
vast geographic area. The present invention provides a
monitoring and reporting system that is referred to as a
Health Check system. The present invention provides a
variety of performance monitoring sensors at each oil rig
in an oil recovery system, and, in certain aspects, for
each centrifuge of an oil rig. The results of selected
diagnostics, which are run on each oil rig and/or on each
centrifuge, are reported to a central server. The central
server automatically populates a database for the oil
recovery system and displays a red/yellow/green/gray
color coded report for each rig and/or for an entire oil
recovery system. The present invention also affirmatively
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alerts appropriate personnel of actions required to
address events associated with an oil rig in an oil
recovery system. The diagnostics performed at each oil
rig are configurable at the individual rig. The central
server need not change its reporting and display program
when changes are made to a heath check at an oil rig. The
present invention provides a dynamic oil rig status
reporting protocol that enables construction and display
of a tree node structure representing an entire oil
recovery system status on a single screen. Preferably,
top level information is presented on a single screen,
and detailed information presented when one drills down
in to other screens. Thus, the present invention enables
rapid visual affirmation of a system Health Check.
A Health Check is an automated test that is running
on the rig and monitoring something, e.g., but not
limited to, a centrifuge, for acceptable performance,
indication of problems, etc. These tests could be applied
to equipments, drilling processes, or an operator's usage
of particular drilling equipment, e.g., but not limited
to, centrifuge(s). The results are then communicated to a
central server located in a service center through a
unique protocol, which allows automatic distribution and
display of information and/or directly from a centrifuge
to an Internet interface. A test program on a rig can be
modified and that change will flow automatically through
communication, storage and display of the resulting
Health Check data for the rig.
The service center based web server allows secure
access to Health Check results. The results are presented
in "top down tree" mode with red/yellow/green/gray
colors. The red color indicates the failure of a test or
flagging an event of interest, the yellow color indicates
that the health test has found some abnormality that may
need attention, green indicates successful completion of
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a test, and gray color indicates inability to conduct a
test. The bottom most node of the "top down tree"
contains the results of a Health Check. The work case
result is successively carried up to the next level,
until topmost node (which in most cases is the drilling
rig, group of rigs or oil recovery system) is reached.
Each Health Check result can be configured to
generate a message (email, phone call, PDA, etc.) to
alert single or multiple persons in case of test failure.
The data transfer protocol is well defined, such that
other development groups or third parties can easily
develop Health Check tests, generate results and feed
information to the central server. Test results are
transferred from the rig to the server using a novel data
protocol that dynamically defines the structure of the
data, that is, the node tree structure of the data by the
naming convention of the protocol. Thus, the results are
simply stored and displayed using the structural
definition provided in the communication protocol. This
allows for extreme flexibility in the definition of new
programs and results to run and report at oil rigs
without requiring a change in the communication protocol,
notification function or the display and storage
functions at the central server. The bottom most nodes in
the tree structure contain test results. Each test comes
into the central server as a record containing node
information as to where the information fits within the
tree structure, an identifier for the test, a test result
(red/yellow/green/gray) and intermediate data such as
error codes, operator entry data and test data
description. Thus, no results processing need occur at
the central server. The central server only archives and
display results and issues affirmative (with
acknowledgement) and regular notifications as required.
Events or conditions can be set for notification,
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thus, once the event or condition occurs and after it is
set for notification, a notification is sent to a
designated person reporting the event of condition. A
list of persons can be associated with each oil rig and
event or condition. A notification can be sent to a cell
phone, PDA or other electronic device. A notification can
comprise a text, audio or video message to a user. A
notification tells the rig status color code, text, aural
or video. A user can call into the central server to
check the status of an oil rig or oil recovery system.
The status returned is a notification message indicating
that the rig is okay or that a problem or condition of
interest has occurred. Thus, the Health Checks are
different than alarms, although alarms (including those
alarms generated by prior or legacy systems) can be used
as inputs to a Health Check where the alarms are
processed and considered by Health Check rather than
sending an alarm immediately to oil rig personnel. Health
Check may indicate that piece of equipment is out of
range and should be replaced in the near future, however,
supercritical alarms can be processed by Health Checks to
generate an immediate notification.
In certain aspects, the present invention (and any
and all steps and/or events described above for any
scenario) is implemented as a set of instructions on a
computer readable medium, comprising ROM, RAM, CD ROM,
Flash or any other computer readable medium, now known or
unknown, that when executed cause a computer or similar
system to implement the method and/or step(s) and/or
events of systems and methods according to the present
invention, either on-site or remotely or both.
The present invention is described herein in certain
aspects for use on drilling rigs, however, numerous other
applications are intended as appropriate for use in
association with the present invention.
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The present invention provides a user interface,
which, in one aspect, is preferably mounted to existing
rig floor structure and also provides a pedestal mount
with adjustable height, for convenient choke operation. A
wireless version is also provided.
The present invention supports real time two way
data communication, e.g., with Varco International,
Inc.'s RigSense and DAQ JVM, and with other commercially
available information systems. In one aspect any sensors
whose data is used by the present invention (for control
and/or display) are directly connected to the present
invention, including, but not limited to, sensors on a
shale shaker or shakers.
In one aspect, when the RigSense system is present
in an embodiment of the present invention, the RigSense
system provides data archiving and expanded data displays
functionality to the present invention. The present
invention provides a user interface integrated into other
systems such as the RigSense system, DAQ JVM and VICIS;
Real Time Well Control, supervisory control specific to
well control tasks; and Automated well control, which may
be entire process or selected sub tasks. One of the
primary impacts perceived on existing products and
services in which integration and/or implementation of
the present invention is performed is additional
capability for taking control of and/or being in control
of the choking operation via a distinct intervention, so
that control is clearly being exercised by users at other
stations and by automated controllers.
A key factor for efficient utilization and
integration of the present invention into the operator's
working environment is the present invention's provision
of manual controls for high frequency user control
actions in lieu of touch screen control consoles.
Additional automated functionality is provided such as
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automatic pressure set control for use in association
with the touch screen and provides benefit in the control
area, particularly in emergency stations. In an
alternative embodiment a touch screen user interface is
provided.
In another embodiment, the present invention is
implemented as a set of instructions on a computer
readable medium, comprising ROM, RAM, CD ROM, Flash or
any other computer readable medium, now known or unknown
that when executed cause a computer to implement a method
of the present invention.
The present invention provides a method and
apparatus for remotely monitoring, analyzing and
affirmatively notifying appropriate personnel of problems
and events of interest associated with an oil recovery
system comprising one or more, e.g. hundreds, of oil rigs
over a vast geographical area or a single rig. The
present invention provides a monitoring and reporting
system that is referred to as a Health Check system. The
present invention provides a variety of performance,
process and equipment monitoring Health Checks and
equipment sensors at each oil rig in an oil recovery
system. The present invention provides a dynamic oil rig
status reporting protocol that enables population and
display of a tree node structure representing an entire
oil recovery system or single oil rig status on a single
screen. Thus, the present invention enables rapid visual
or aural affirmation of a system Health Check.
Health Checks are not the same as alarms. An alarm
is an immediate notification to an operator that a known
unacceptable condition has been detected, requiring the
operator's awareness of it and often some action by the
operator. A Health Check may use alarms in its logic, but
it is by nature different than an alarm. A heath check is
more general and more diagnostic than an alarm, and does
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not require immediate action, at least not on the oil
rig. In the present invention, a problem is reported to a
central server for reporting and diagnosis to service
personnel. A Health Check can apply to any equipment
component or process, sensors, control systems, operator
actions, or control processes, etc.
The Health Check system comprises software
containing test logic. The logic is configurable so that
inputs, outputs and logic can be selected by a user to
test and look for any condition or event associated with
an oil rig or oil recovery system. The overall system in
certain aspects comprises Health Checks running in real
time on a computer at an oil rig and a communications
network connecting the oil rig to a central server to
move data from the rig of a group of rigs to the server.
The server displays the results in hierarchical form. The
server sends commands, application programs and data to
the rig from the server.
The Health Check system of the present invention
further comprises, in certain aspects, a central database
populated with dynamic status reported from oil rigs
comprising an oil recovery system. The present invention
further comprises a web page display for efficiently
displaying Health Check results associated with a test, a
rig, an area or an oil recovery system. The web page
results can be displayed on a computer, cell phone,
personal data assistant (PDA) or any other electronic
display device capable of receiving and displaying or
otherwise alerting (e.g., sound notification) a user of
the status of the data. The preferred screen is a color
screen to enable red/green/yellow/gray display results.
Results can also be audio, video or graphically encoded
icons for severity reports, e.g., an audio message may
state audibly, "situation green", "situation red" or
"situation yellow" or display a particular graphical
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icon, animation or video clip associated with the report
to demonstrate a Health Check severity report. The
present invention enables drilling down (that is,
traversing a hierarchical data structure tree from a
present node toward an associated child or leaf node),
into a tree of nodes representing diagnostic status, to a
node or leaf level to access additional information
regarding a color coded report.
The present invention also provides a notification
system to immediately inform service personnel of
problems as necessary, such as a message or email to a
cell phone or pager or computer pop up message. There is
also a receipt affirmation function that confirms that a
notification message was received and acknowledged.
Secondary and tertiary notifications are sent when a
primary recipient does not acknowledge an affirmative
notification within a configurable time limit. A severity
report associated with a given problem is represented by
a blinking color when it is unacknowledged and remains a
blinking color until the given problem is cleared and
returns to green or clear status. Severity reports once
acknowledged change from blinking to a solid color.
Reports that have been acknowledged by one user may be
transferred or reassigned to another user upon
administrative permission by a system supervisor or by
requesting permission to transfer a second user and
receiving permission from the second user. A system
supervisor can also display a list of users and severity
reports being handled by the user, that is, a list of
acknowledged and in progress severity reports assigned to
a particular user to view and enable workload
distribution to facilitate reassignments for balancing
the work load.
A dispatch may assign a work order to a group of
particular severity reports. Once the work order is
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completed the system checks to see if the nodes
associated with the work order have been cleared. The
work order provides a secondary method for determining if
nodes associated with a work order have been cleared
after a work is complete. The system administrator
software program can also automatically check the work
order against the node state for a system check.
The advantages provided to the customer of a
preferred Health Check system are substantially less down
time due to the present invention's Health Check's
ability to find or anticipate problems earlier and fixing
the problems faster, ideally before the customer becomes
aware that a problem has occurred. The present invention
reassures the customer that the Health Check system is
always on the job and monitoring and reporting on the oil
recovery system twenty four hours a day, seven days a
week. A customer or system user can always call in and
confirm the status of an entire oil recovery system or
single rig with a single call to the central server or a
rig and receive a situation report, that is situation
red, yellow, green or gray for the oil recovery system or
single rig, as requested. The present invention enables
more efficient use of operational service personnel. The
present invention finds and reports problems, potential
problems and trigger events of interest, which enables
rapid response and recovery in case of actual and/or
potential equipment or operator malfunctions or the
occurrence of a particular event. The present invention
also helps to find problems at an early stage when the
problems are often easier to fix, before catastrophic
failure, thus creating less impact on the customer's oil
recovery system or individual oil rig. Health Checks
according to the present invention provide a method and
apparatus for providing an application program that acts
as an ever vigilant set of eyes watching an entire oil
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recovery system or single rig to ensure that everything
is okay, that is, operational.
In certain embodiments, all results for each oil rig
in an oil recovery system or individual oil rig or
equipment, e.g., but not limited to, a shaker or shakers,
are worst case combined so that the worst case severity
report bubbles to the top of the reporting tree and is
reported as the status for an entire oil recovery system,
oil rig(s), event of interest, process, or equipment
being analyzed. As discussed above, red is a worst case
severity report, followed by yellow severity report and
then green is the least severe report. Gray indicates no
data available. Thus, if one or more tests reporting a
red status is received from an oil rig, the red status
bubbles up past all yellow and green status reports and
the status for the rig and the entire oil recovery system
in which the rig resides is shown as red. Once the red
report is cleared, yellow reports, if any, bubble up and
the status of the oil recovery system, rig or equipment
being viewed is shown as yellow, if a yellow report is in
a node tree transmitted from any oil rig in an oil
recovery system. The status for a single oil rig bubbles
up the worst case report as well, however, localized to
the single rig or rigs under investigation, unless
grouped. When grouped the worst case status for the group
is reported. For example, if three rigs were reporting
the following scenario is possible: Rig 1 reports red,
rig 2 reports yellow and rig 3 reports green. The status
for a group selected to include rigs 1, 2 and 3 would be
red. The status for a group selected to include rigs 2
and 3 would be yellow. The status for a group selected to
include rig 3 only would be green. Subsections within a
rig can also be selected for a color coded status report.
Preferably, the gray is not cleared. Usually, if the test
were not conducted for any reason, the status would take
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gray color.
The present invention enables testing at the nodes
of a bottom up tree structure representing an oil
recovery system, a single rig therein, or an equipment in
an oil rig, wherein the nodes carry the results to the
top for easy visualization and use. The present invention
also provides a dynamic reporting protocol for data
transfers from an oil rig to a central server wherein
level identifiers are provided to transfer data and its
structure in a single packet transfer, thus enabling
dynamic data base population and display of reports from
an oil rig. The results are presented on a web page or
reported to cell phones, computers, pagers, personal data
assistants or otherwise affirmatively reported other wise
to appropriate personnel. In a preferred embodiment,
reports are acknowledged by a first recipient or a second
recipient is selected for receipt of the report when the
first recipient does not acknowledge receipt, and so on,
until a recipient has received and acknowledged the
report. Alternatively multiple recipients may
simultaneously get the notification.
The present invention is automatically scaleable and
extensible due to the modular and dynamic nature of its
design. Tests can be easily created, added or deleted and
parameters added or modified on an oil rig equipment test
or Health Check without reprogramming or changing the
central server's database population, data reporting and
data display applications. The reporting can vary between
broad coverage and specific coverage, that is, a status
report can included data for an entire oil recovery
system comprising over 100 oil rigs and/or specifically
report status for a single oil rig of interest
concurrently.
The present invention provides early warning of
potential and actual failures and also provides
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confirmation of product performance and usage. A set of
automated Health Checks and diagnostic tests is selected
to run in real time on an oil rig. Status from the test
is reported continuously via a communication link between
the oil rig and a central server. The present invention
provides insight and analysis of equipment, processes and
equipment usage on an oil rig. The present invention
monitors alarms and parameter limits to assess necessary
action and perform affirmative notification of
appropriate personnel.
The present invention provides quick response, real
time monitoring and remote diagnostics of the automation
and control systems running on oil rigs comprising a
fleet of oil rigs or an oil recovery system to achieve
maximum rig performance while maintaining optimum
personnel allocation. A service center is connected to
the oil rigs through an Internet based network. System
experts make real time data and logged data from the oil
rigs available for perusal and analysis in a central
facility or at distributed locations. The web site of the
present invention provides access to current operational
status as well as to historical operation and performance
data for each of the rigs comprising an oil recovery
system.
Health Check tests are configurable so that new
tests can be created, added or deleted and parameters
changed for execution at an oil rig without the necessity
of programming. A simple user interface is provided
wherein a user at the central server or at an oil rig can
select a test from a library of existing tests, or create
a new test using a scripting language, natural language
interface or pseudo language is provided which generates
a script defining inputs, outputs and processing logic
for a test. The script is compiled and sent to the rig
for addition to existing Health Checks running on the
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rig. The user interface also enables modification or
addition and deletion of parameters associated with a
Health Check or test.
Notifications can be an immediate message when a
problem is detected or an advisory notification. The
notification is sent to expert service personnel
associated with the central server or can be directed to
a service manager or local service person closest to the
rig needing service. For each rig and problem type, a
particular person or service personnel category is
designated for receipt of a notification. Secondary and
tertiary backup personnel and personnel categories are
designated as a recipient for each notification.
Affirmative notifications must be acknowledged by the
recipient so that the problem is acknowledged and someone
has taken responsibility for the problem. If an
affirmative notification is not acknowledged within a
configurable time period, then a secondary or tertiary
recipient is notified until the problem is acknowledged.
Reliability reports are generated by the present
invention showing performance summaries for oil rigs,
comprising up time, response, problems detected and
solutions provided. These reports provide an objective
basis for formulating an evaluation of the Heath Check
system's efficiency.
The results from a rig include processed inputs from
the rig. No processing is required at the central server,
other than display, storage and alerts to appropriate
personnel. The oil rig Health Checks and tests are
configurable so no programming is required to implement a
new test or change logic or parameters for an existing
test. A field engineer or central server personnel can
add a new test without requiring a user to perform a
programming change. The present invention provides a
local or remote user interface, which provides a simple
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interface for describing a test and logic. The interface
comprises an iconic presentation, pseudo language, script
or a natural language interface to describe a test's
input(s), processing logic and output(s). The user
interface interprets a user's inputs and converts the
user's input into a scripting language. The script
language is compiled and sent to the rig on which the new
or augmented test is to be performed. The new test is
added to a library of tests from which a user may choose
to have run at a rig. Test modules can be deleted, added,
parameters changed, and updated from the oil rig, the
central server or from a remote user via a remote access
electronic device.
Turning now to Fig. 10, a preferred embodiment of
the present invention is shown illustrating a global
overview 200 of all rigs comprising an oil recovery
system. As shown in Fig. 10, a map pinpoints geographic
locations of the rigs in the system of interest. A web
page display is presented on a personal computer or PDA.
The web page generated by the central server presents a
geographic view of an oil recovery system. In Fig. 10,
rig number 563 (702) and rig number 569 (707) are shown
with a red status, indicating that a condition or
reporting event of interest has occurred at rig number
563 and number 569. Rig number 569 (706) is in Canada and
rig number 563 (711) is in the United States. Rig number
571 (709) has a yellow status and rig number 567 (708)
has gray status. All other rigs shown in Fig. 10 have a
green status. When a system user clicks on rig number 569
(707) or the Canadian region, the display of Fig. 11
appears. Fig. 11 shows the Canadian region, which
includes rig number 569. Notice that rig number 570 has a
green status is now displayed on the more detailed
Canadian region display. The green status geographical
indicator for rig number 570 is suppressed and not shown
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in the broader display of Fig. 10 so that the more severe
red status of rig number 569 would be immediately visible
and evident on the display of Fig. 10. Once a user
implicitly acknowledges the red status for rig number 569
by clicking on rig number 569, the present invention
displays the less severe status of rig number 570. Thus,
the more severe status of rig number 569 bubbles up in
the geographical display and is displayed first at a
higher level in the geographical display hierarchy. Note
that the green status indicator of rig number 570,
however, is shown in the panel 704 of Fig. 10 and Fig.
11. Thus, the present invention presents a hybrid display
in which all Health Check results are available in the
panel 704, but worst case results are presented in the
geographical displays of Fig. 10 and Fig. 11.
Turning now to Fig. 12, the status display 724 of
Fig. 12 for rig number 569 is shown when a user clicks on
rig number 569 in Fig. 10 or Fig. 11. Fig. 12 illustrates
that a rig number 569 component, "RigSense" has a red
indicator. The Magnifying Glass icon 722 shown adjacent
red indicator 730 indicates that more information is
available regarding the red indicator 730. There are also
additional panel displays 716 and 718, which are
configurable, which perform additional informative
functions. A summary panel 720 is displayed for rig
number 569. The summary status panel contains operator
reports from the oil rig. These operator reports are
useful in diagnosing status and formulating a plan of
action or notification. An AutoDriller status panel is
also displayed. Note that the Weight on Bit (WOB)
indicator 717 is red in the AutoDriller status panel. A
driller adjustable parameters panel 718 is also
displayed.
Turning now to Fig. 13A, continuing with rig number
569, clicking on the red indicator for RigSense status in
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Fig. 12, brings up the display for the RigSense system
panel status 740 as shown in Fig. 13A. Note that the
device message block 743 may contain a part number to
expedite repair of a failure as reported. The particular
part number and or drawing number necessary to perform a
given repair associated with a given problem or severity
report may be difficult to find in a vast inventory of
parts and part numbers and drawings associated with a
given failure. Otherwise, the recipient of a failure
report may have to search via key words through a vast
inventory of parts, part numbers and drawings associated
with a given failure. Moreover, the user may not be
familiar with a particular vendor's part numbering
system, thus, provision of the part number is a valuable
expedient to trouble shooting.
Fig. 13A shows that the sensor group device status
742 is red with a Magnifying Glass icon 746 indicating
that more information is available for the red sensor
group device status indicator 742. In an alternative
embodiment, as shown in Fig. 13B, a pop up message 746a
appears along with the Magnifying Glass stating "Click on
Magnifying Glass for more details." Clicking on the red
sensor group 744 device Magnifying Glass 746 brings up
the display 750 of Fig. 14, showing a detailed status for
the sensor group device status. Note that there are two
red indicators shown in Fig. 14 for device status in the
sensor group as follows: "Pump 3 Stroke Count Sensor" 756
and "Hookload Sensor" 754. Note that the Pump 3 red
device status indicator has an informational comment 752
in the operation column of the display of Fig. 14,
stating "Intermittent Loss of Signal." The Hookload
Sensor red device status indicator present an adjacent
Magnifying Glass icon 758 with a message indicating that
more information is available for the device status of
the Hookload sensor by clicking on the Magnifying Glass
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icon. Clicking on the Magnifying Glass indicator 758 for
the Hookload sensor brings up the Hookload sensor panel
766 of Fig. 15, which shows that the device name
"Barrier" 760 had a red device status indicator 762. The
red device status for the Barrier displays an Operation
message 764, stating, "Excessive ground current". Each
colored indicator and accompanying operation message
shown in the preferred displays illustrated in Figs. 10 -
appeared in line of the Health Check performed at an
10 oil rig and sent to the server in the structured protocol
of the present invention.
Fig. 16 illustrates a Driller Adjustable parameters
display 710 with two red indicators showing that Drill
Low Set Point 712 and Upper Set Point 714 are Outside
15 Range. A Drilling Tuning parameters panel 716 is also
displayed. Both panels indicate the current value,
changed indicator and outside range indicator for each
parameter displayed in the respective panels of Fig. 16.
The display of Fig. 16 is an alternative tabular display
for rig status for a single rig. Fig. 17 illustrates a
configuration or driller adjustable parameters status
panel 810 for rig numbers 178 189. The display of Fig. 17
is an alternative tabular display for rig status for
plurality of rigs, e.g., rigs 178 189. Turning now to
Fig. 18, a data acquisition system 801 is shown in an oil
rig environment connected to a plurality of legacy or
Heath Check sensors ("SENSORS") which, in certain
aspects, include sensors on a centrifuge or centrifuges
which gathers data from the group of sensors monitoring
the rig equipment, parameters and processes. The data
acquisition system 801 sends the acquired data from the
sensors to a computer 804 on which the preferred Health
Check application of the present invention is running.
The application of the present invention performs Health
Checks logic on the acquired data and reports the results
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in the structured protocol to a user via satellite 806 or
some other form of electronic communication. A user may
monitor health check status and receive notifications via
an electronic receiver 808, diagnostic station 807 or
mobile in field service vehicle 805. Alternatively the
shaker(s) may have a direct connection from a shaker
computer CPR to the data transmission system.
The present invention is also useful for Process
Monitoring, that is, to determine that equipment is being
used properly to perform a designated process. For
example, if rig operators are using an "override" during
a certain system state indicative of a certain process,
which is supposed to be run automatically rather than
manually overridden, the present invention can perform a
health check to detect this event of interest and report
it to the central server. Knowledge of this occurrence
enables central server personnel to detect and correct
the inappropriate action of the operators. Moreover, the
test to detect the inappropriate override stays in the
system so that if new operators recreate the problem or
trained operators backslide into using the manual
override inappropriately, the central server personnel
will be notified so that the problem can be address
again. Thus, the Health Check system builds a cumulative
base of operational checks to insure that a process on a
rig or oil recovery system runs in optimal fashion.
Turning now to Fig. 19, Fig. 19 is an illustration
of a preferred Health Check system reporting health
checks of multiple equipments, processes or systems from
multiple oil rigs to multiple users. It is to be
understood that any equipment's, device's, or apparatus's
controller or associated computer may be employed for the
system as shown in Fig. 19, but the specific item shown
schematically is a controller and/or computer for a
centrifuge. As shown in one aspect the centrifuge
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controller and/or computer (e.g. but not limited to PLCs
54p, 56p, 46p described above) is in communication with a
Rig Health Commander, a Health Check Engine, and a user.
Optionally, the centrifuge controller and/or computer can
be in direct communication via the Internet or a similar
network with another entity, device, and/or user.
Turning now to Fig. 20, the results of the tests are
reported to the central server in a special protocol that
contains heath check results data and describes the
manner in which the data is constructed so that the data
can be placed in a logical data structure or tree format
and displayed. Note that the root node 810, usually an
oil rig has a designation of "00". The first level of
nodes 812, 813 etc. under the root node are named Aa, Ab,
Ac, Ad, etc. Each subsequent layer of node is named with
the name of the parent node followed by a designation of
the current node. For example, as shown in Fig. 20, for a
rig number 569, the root node 810 is named "00", the
first level of children nodes under the root node are
named Aa 812 and Ac 813. The children of node Aa 812 are
named AaBa 814, AaBd 1116, AaBe 818 and AaBf 820 as
shown. The children of child node AaBa are named AaBaC1
822, AaBaC2 824, AaBaC3 826 and AaBaC4 828. The children
of node AaBaC5 830 are named AaBaC5Dg 832, AaBaC5Dp 834,
AaBaC5Dq 836 and AaBaC5Ds 838. A new test could be added
to rig 569 number and the Heath Check status could be
reported under node AaBaC5Dx 840.
Changes to the Health Checks running on any or all
rigs does not require changes to the display or data base
population application because the preferred
communication protocol defines the data base layout and
display layout. The leaf nodes of the tree structure
represent Health Check results. Each node contains a test
identifier, test result
(red/yellow/green/gray),
intermediate data, user entered data and test
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description. Trouble shooting comments are provided at
the central server based on reported errors. Test error
codes are included in the node so that messages
associated with the error codes are displayed to the
appropriate user. Alternately, trouble shooting and other
information can also be generated and appended to the
results of the tests at rig site. Thus, no processing to
determine rig status is done at the central server.
Notifications are sent when deemed necessary by the
application. Notification logic is configurable by
service personnel at the central server or at the oil
rig. Notification logic dictates that notifications are
sent when an event occurs and the event has been selected
for reporting as a notification to a user. The
notification logic and a list of appropriate notification
recipients in order of priority, that is, who to contact
first, is retained at the central server. The event can
be a report on an equipment status, process execution or
an operational item. A user can check in with the central
server of present invention to obtain a real time report
of the status of an oil rig or multiple oil rigs. The
requesting user will receive a severity report message
indicating the status of the rig, for example, "okay" or
"red/yellow/green/gray."
Figs. 21A and 21B show a control cabinet 500 for a
control system (e.g., but not limited to, a control
system as in Figs. 2, 2A, and 3) with an enclosure 502
made, in one aspect, e.g. of metal, e.g. carbon steel or
stainless steel (or, optionally, made of fiberglass or
composite material). The enclosure can be made of
materials and parts suited for either hazardous or
nonhazardous locations. The control cabinet 500
distributes facility (rig) power through the use of
variable frequency drives (VFD's) to a centrifuge and a
pump (e.g. VFD's as in Fig. 2). A centrifuge can be
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controlled using a human machine interface, a touch
screen apparatus (or screens) 504. The screen apparatus
or apparatuses can be in a cabinet and/or at another
location or position.
The enclosure 502 has feet 506 and lifting eyes 508.
Optionally a window 511 protects the touch screen 504 and
is movable on hinges 513.
Receptacles or glands receive cables to provide
power to the VFD's for the motors (centrifuge bowl motor,
centrifuge conveyor motor, pump motor). A gland or
receptacle 519 is for a control line (e.g., at 24 VDC or
120 VAC) which can be connected to centrifuge safety
devices (e.g. an emergency stop safety vibration switch,
and torque arm which measures torque). A receptacle or
gland 512 receives inlet an inlet power cable or cables
for certain items in the cabinet 500. The control power
transformer 593 receives input power (e.g. at 120, 380,
480, 575, or 690 VAC) from the power terminals 534. Power
cables for the motors pass through glands 516, 518.
Fig. 22 shows a control cabinet 500a, like the
control cabinet 500 (like numerals indicate like parts).
The control cabinet 500a is used to control two
centrifuges and has two touch screen apparatuses 504 and
two control panels, one for each centrifuge, as described
below.
The control cabinet 500 houses a control panel 600
(see Fig. 23) and its related apparatuses, structures and
devices, (shown schematically in Fig. 21A) which are in
communication with the touch screen apparatus 504. There
are two control panels 600 in the control cabinet 500a,
Fig. 22, one panel for each centrifuge for independent
control of each centrifuge.
The control panel 600 includes controls for at least
one, two, or more air conditioning units 517 ("A/C") with
on/off switches or circuit breakers for each unit and an
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internal temperature gauge 522 ("INTERNAL TEMP GAUGE")
which can be inside and/or outside the cabinet. In one
aspect, the gauge reads temperatures between -50 degrees
C and 50 degrees C. Multiple heaters or one heater can be
housed in the control cabinet 500. There are three
heaters 523 in series in the control cabinet 500 which
turn on automatically if the temperature falls below zero
degrees C. An appropriate circuit breaker or breakers are
used with the heater(s). An exterior temperature gauge
591 provides a visual indication of the temperature
external to the cabinet 500. The control cabinet includes
a digital thermometer 592 in communication with the touch
screen 504 which provides a visual indication of the
temperature within the cabinet. The air conditioning
units can be started automatically when the temperature
inside the cabinet rises above a threshold point.
Similarly, the heating units can be automatically started
when then temperature inside the cabinet falls below a
certain threshold point.
Optionally, the system of the control cabinet 500
can be operated by remote control via a wireless ethernet
switch 524 connected to an antenna 525. A push-pull
emergency button 526 ("EMERG STOP") applies power to the
controls for the centrifuge and other apparatuses (pull
out) or removes all power from the controls, etc. (push
in). The system 500a has such a button for each
centrifuge. The emergency stop can be located on the
cabinet, on the centrifuge, or both.
The touch screen apparatus 504 is a computer-based
apparatus with a computer or PLC, programmable media and
associated hardware and software and a touch screen
which, in one aspect includes a "stop centrifuge" button.
During normal operations the centrifuge and feed pump are
stopped by pressing the "STOP CENTRIFUGE" buttons on the
touch screen 504 and not by pressing the Emergency Stop
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button on the control cabinet. When the "STOP CENTRIFUGE"
button in the touch screen 504 is pressed, the VFDs ramp
to a stop. When the Emergency Stop button is pressed, the
VFDs shut down completely and the centrifuge and feed
pump coast to a stop. It takes longer to coast to a stop
than to ramp to a stop. Once the centrifuge stops
rotating, the Emergency Stop button can be pressed. The
Emergency Stop button should not be pulled out re-
applying power to the VFDs when the centrifuge is slowing
down.
A power panel 527 in the control cabinet 500
contains a contactor 527a (or circuit breaker) and a
terminal 534 that supply the power for the VFDs and the
various items in the cabinet 500. A supply power cable
enters the enclosure 502 through the receptacle 516 and
is connected to the contactor (or "POWER PANEL") 527.
Power from the power panel is supplied to each VFD.
The control cabinet 500 houses three VFDs, two for
the centrifuge motors (bowl VFD, conveyor VFD) (VFDs 528,
529) and one for the pump (VFD 530). Each VFD has an
internet protocol card 531, e.g., a Modbus TCP/IP card
for communication with the touch screen 504 via an
Ethernet cable and switch. Using appropriate IP
addresses, this insures that the touch screen apparatus
504 runs the centrifuge it is programmed to run (or one
it is chosen to run) and not some other centrifuge with
different parameters. There are six VFDs in the control
cabinet 500a, three for each centrifuge/pump system. Each
VFD includes a keypad 532 which can be used to program
the VFD and display information (on the touch screen
apparatus 504) about the VFD during operation. With
appropriate touch screen apparatus programming
(programming of the programmable media that is part of
the touch screen apparatus) any suitable VFD may be used.
Optionally any desired number of VFD's can be housed in
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the cabinet (e.g. VFD's for two, three, four or more
centrifuge systems and/or shakers, agitators, dryers,
augers, etc.
Each VFD may have a heat sink apparatus 533 for
dissipating the relatively large amount of heat generated
by a VFD in use. Also, high ambient temperature and
direct sunlight can heat up the interior of a control
cabinet. Each VFD monitors its respective heat sink 533.
In one aspect, if the heat sink temperature approaches a
preset maximum, e.g., but not limited to, 105 degrees C,
the VFD will shut down.
The power panel 527 is wired to power terminals 534.
The control cabinet 500 has one, two, or more thermostats
535 for controlling the air conditioning unit(s) 521 and
controlling the heater(s) 523. One thermostat may be an
ambient temperature thermostat that turns the heaters 523
on and off while another thermostat is a safety backup
thermostat which prevents the cabinet from over heating
in case the ambient temperature thermostat does not turn
the heaters off. The control power transformer system 593
connected to the power terminals 534 provides power at an
appropriate voltage to the items in the cabinet. In one
aspect, there is one thermostat for each air conditioner.
The ethernet switch 524 provides communication
between the VFDs and the touch screen 504. The switch 524
is powered by a 24 VDC power supply 524p. Wiring
terminals 537, on a door 505 of the control cabinet 500
supply power to the heater(s) 523, thermostats 535, and
emergency stop circuits.
Fuses 538 protect the control and power circuits.
Figs. 24 - 29C illustrate a typical method 580
according to the present invention for controlling a
centrifuge (e.g. using a system as in Figs. 2, 2A, 3,
21A, and 23). To start ("START") the method, power is
applied to a touch screen system (like the touch screen
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apparatus 504) (e.g. power applied to the touch screen at
24 volts from a 24 volt power supply). The touch screen
system 504, in one aspect, has programmable media
programmed with the operational logic software downloaded
into the media and has a memory, e.g. compact flash
memory and/or non-volatile memory, where predefined
parameters are saved which enables the system to run a
previously-saved operation (e.g. after it loses power).
In the "Continue Operation?" step, if it is desired to
retain the saved settings, "YES" is pushed and the method
advances to an operations page ("GO TO OPERATIONS PAGE")
for monitoring operations, and displaying operation
parameters, and with method steps taken to run the
centrifuge ("RUN CENTRIFUGE"). When running is finished,
the function is completed (executed).
If saved settings are not desired ("NO") timers and
settings are reset ("RESET ALL TIMERS AND PREVIOUS
SETTINGS"); a language is selected ("SELECT LANGUAGE")
(e.g. English, French, Spanish, Italian, Russian, German,
Chinese, Hebrew, Thai, Japanese or Korean or any other
suitable language); and the system time is set e.g. by a
user ("SET SYSTEM TIME") for the particular world time
zone to insure that the system historical program in the
system and/or on a removable flash card or portable drive
selectively connectible to the touch screen is
synchronized to the proper time zone.
Once the time is set, a centrifuge is selected
("SELECT CENTRIFUGE"; Fig. 25); a pump is selected
("SELECT PUMP"; Fig. 26); an operation is selected
("SELECT OPERATION"; Fig. 27); and a control method is
selected ("SELECT CONTROL METHOD"; Fig. 28). The
centrifuge is run ("RUN CENTRIFUGE") with the pump
running (Fig. 29A); with torque protection (Fig. 29B);
and with fault protection (Fig. 29C). It is within the
scope of the present invention to control and run any
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centrifuge, e.g., but not limited to, any triple drive
centrifuge and can, in one aspect, achieve this without
the need for reprogramming the touch screen apparatus.
To begin ("START") the select centrifuge step, Fig.
25, either a specific known centrifuge is selected by
model (e.g. HS-2000) or another centrifuge is selected
("IS OTHER SELECTED"). If a known centrifuge is selected,
its preprogrammed settings already entered into the
system (e.g. a particular bowl pulley ratio and gearbox
ratio) are applied in the operating system. If another
centrifuge is selected, parameters are entered into the
system by a user (e.g. gearbox ratio, bowl inner
diameter, bowl pulley ratio, minimum rpms for bowl of the
centrifuge, and minimum rpms for the centrifuge's
conveyor). For a known centrifuge (not "another
centrifuge") minimum bowl and conveyor rpms are preset.
In one particular aspect, the bowl is set at a minimum of
800 rpms and the conveyor motor is set at a minimum of
400 rpms; and, in another aspect, the bowl is set at 2500
rpms or at 3000 rpms and the conveyor motor at 100 rpms,
250 rpms, or at 460 rpms.
To begin ("START") pump selection, Fig. 26, a
particular type of pump system is selected using the
touch screen (as is done in the other steps of the
method); e.g. a centrifugal pump or a PDP pump. If
neither of these types of pump are chosen, a flow meter
is used to read the pump's flow ("IS FLOW METER
SELECTED") and the system is calibrated to read the
selected pump's flow to the centrifuge in gpm.
When a PDP pump is selected (Fig. 26A) the method
beings ("START") by entering the type of PDP pump (e.g.
Mono Blok; Seepex BN 130-6L; or a custom pump). For known
pumps, parameters (motor gearbox ratio and gpm/rpm ratio)
are pre-set. For a custom pump, gpm/rpm ratio and motor
gearbox ratio are input by the user. then this step is
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done ("END").
To begin to select a particular operation ("START",
Fig. 27) one of a variety of choices is made; e.g.,
barite recovery, lower gravity solids removal, dewatering
mode, or idle ("IDLE PAGE"). Once an operation is
selected, using the touch screen, pre-set parameters take
effect, e.g. as the following: maximum g force of the
bowl (maximum bowl rpm); maximum conveyor rpm; maximum
bowl/conveyor differential; minimum bowl/conveyor
differential; starting G force; starting rpms; starting
differential (depending on centrifuge selection). If idle
operation is selected, starting bowl rpm and starting
conveyor motor rpm is preset (or optionally input by the
user). In one aspect, idle is selected to allow the
centrifuge to run at low speed while preserving the
interior wall cake in cold climates (e.g. to prevent
plugging).
To begin ("START", Fig. 28) to select a control
method, the user inputs a choice of one type of control
method (control rpms; Fig. 28B) or G-force differential
control (differential is the bowl-rpm conveyor-rpm
differential; Fig. 28A).
The control rpm sub-method is illustrated in Figs.
28B, 28F, 28G and 28H. The G-force differential control
method is illustrated in Figs. 28A, 28C, 28D and 28F.
In the G-force-differential control mode (Fig. 28A)
starting the centrifuge ("START"; "START CENTRIFUGE")
ramps the bowl and the conveyor to predetermined speeds
based on the operation. The bowl speed may be changed
(Fig. 28F); the conveyor speed may be changed (Fig. 28G);
the conveyor motor direction may be changed (Fig. 28H);
and the centrifuge may be stopped (as in Fig. 28E).
To begin ("START"; Fig. 28F) to change the bowl
speed, a user chooses between inputting: a new speed
("ENTRY") greater than the current speed; and a new speed
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less than the current speed in rpms. If a new entry is
chosen and it is not greater than the maximum rpm speed,
and does not break the maximum bowl/conveyor differential
limit, then it is accepted ("ACCEPT ENTRY") and this step
is over ("FINISH"). If a new entry is not greater than
the current entry and is not less than the current entry,
("NEW ENTRY < CURRENT ENTRY"), it is accepted. If the new
entry does not exceed the minimum or maximum differential
limit, and it does not exceed the maximum or minimum
speed allowances, ("DOES NEW ENTRY BREAK MIN DIFFERENTIAL
LIMIT ?"), it is accepted.
As shown in Fig. 28F, entries not satisfying the
conditions stated in the paragraph above are rejected
("REJECT ENTRY") and the rpm does not change.
Fig. 28G illustrates steps in changing the conveyor
speed (and, hence, the bowl/conveyor rpm differential)
beginning ("START") with a system response to the
question whether the conveyor motor is moving in reverse
("CONVEYOR IN REVERSE"). A new conveyor speed is accepted
if, as shown in Fig. 28G, conditions are satisfied
regarding: the new entry's relation to the current entry
- greater than or less than the current entry; the new
entry's relation to the maximum allowed speed and the
minimum allowed speed; and whether the new entry violates
the maximum and minimum differential limits.
Beginning a step to change the conveyor motor
direction ("START", Fig. 28H), the system checks whether
the conveyor motor is running in reverse ("IS CONVEYOR
MOTOR IN REVERSE?"). A change in direction is not
permitted if the feed pump is running ("IS FEED PUMP
OFF"); if the maximum or minimum differential limit is
violated; or if bowl torque and conveyor torque exceed a
preset level; or if the conveyor motor is not in reverse
and: if the feed pump is off ("IS FEED PUMP OFF") and the
direction change will affect the maximum differential
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limit (bowl-conveyor speed differential); or with the
feed pump off and the differential not changed, the
centrifuge torque is not below an allowed limit ("IS
CENTRIFUGE TORQUE BELOW ALLOWED LIMIT"). If the
centrifuge torque is below the allowed limit, and the
differential limit is not exceeded and the pump is off,
the change direction command is executed ("CHANGE
DIRECTION ENABLED") and the step is done ("FINISH"). If
the feed pump is off and the direction change will affect
the minimum differential limit ("WILL CHANGE AFFECT MIN
DIFFERENTIAL LIMIT"), the change is not allowed ("CHANGE
DIRECTION DISABLED"). If the feed pump is off, the
minimum differential limit is not affected, and the
centrifuge torque is not below the allowed limit, and the
differential limit is not exceeded and the pump is off,
the direction change is not allowed and, if the torque is
below the allowed limit the direction change is allowed
("CHANGE DIRECTION ENABLED").
In the G-force-differential control mode of Fig.
28A, in starting the centrifuge ("START CENTRIFUGE") the
G-force can be adjusted ("ADJUST G FORCE"; Fig. 28C) or
the differential (bowl-conveyor speed differential) can
be adjusted ("ADJUST DIFFERENTIAL") (Fig. 28D). The step
of stopping the centrifuge is illustrated in Fig. 28E.
When this is executed, then the step is done ("FINISH").
As shown in the step of Fig. 28C, there being a
minimum speed below which the control system will not let
the centrifuge conveyor motor or the bowl motor go, the
differentials referred to in Fig. 28C depend on these
minimum allowable speeds. There is a differential for
when the conveyor motor is in reverse:
Differential (Conveyor Motor in Reverse) =
[(Sqrt(GFORCE*70414/Bowl_ID) I+Conveyor Motor
RPM]/GB_Ratio
and a differential for when the conveyor motor is in
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forward:
Differential (Conveyor Motor in Forward) =
[(Sqrt(GFORCE*70414/Bowl_ID) 1-Conveyor Motor
RPM]/GB_ Ratio
"Sqrt" is square root. "GFORCE" is the G-force on the
bowl. "Bowl ID" is the inside diameter of the bowl.
_
"Conveyor Motor RPM" is the speed in rpms of the conveyor
motor. "GB Ratio" is the gear ratio for a gear system
_
between the bowl and the conveyor. The system queries
regarding whether the new entry will be greater or less
than the current entry and how the new entry will affect
the allowed limit on the differential (Fig. 28C). With
other condition met, if the new entry will not increase
the differential beyond the allowed limit, the new entry
is accepted (Fig. 28C, "ENTRY ACCEPTED"); and if, with
other conditions being met, the new entry will not
decrease the differential below the allowed limit, the
new entry will be accepted. Otherwise, the new entry will
be rejected ("ENTRY REJECTED"). Once the entry is
accepted (or rejected) this step is done ("FINISH"). Once
the entry is accepted (or rejected) this step is done
("FINISH"). If a new entry is rejected, a message that
the attempted new entry is invalid will appear on the
touch screen ("HMI").
Regarding the speed differential between the
conveyor and bowl, there is a "deadband." The centrifuge
cannot operate in this deadband. When the deadband is
breached, a differential value change (speed
differential) will cause the conveyor motor to drop below
the allowed speed (rpm) of the conveyor motor. Deadband
breach occurs when the differential value decreases, and
in forward motion this occurs when the differential value
increases. The highest and lowest differentials (in the
two bottom blocks of Fig. 28D above "FINISH") depend on
the current G-force setting. The steps shown in Fig. 28D
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are designed to prevent the centrifuge from operating in
the deadband and can change conveyor motor direction to
skip the deadband.
Fig. 28E presents steps in a sub-method for stopping
the centrifuge. It should be kept in mind that it is
always possible to effect an emergency stop of the
centrifuge.
To begin the sub-method of Fig. 28E ("START"),
"stop" is touched on the touch screen ("PRESS STOP") and
the feed pump is turned off ("TURN OFF FEED PUMP"). Once
the feed pump is off ("IS FEED PUMP COMPLETELY STOPPED
?") and the torque on the bowl and torque on the conveyor
are below pre-set levels ("IS TORQUE BELOW ALLOWED LIMIT
?"), the system enables stopping of the centrifuge
("ENABLE STOP CENTRIFUGE") and the centrifuge stop button
is pressed ("STOP CENTRIFUGE"). When the centrifuge
stops, this sub-method is done ("FINISH").
If the feed pump is not stopped or the torque is not
below the allowed limit, the centrifuge will not be
stopped ("DISABLE CENTRIFUGE STOP").
The feed pump is stopped so that no more solids are
pumped to the centrifuge. A lower torque indication (e.g.
below a certain percentage of maximum possible torque,
e.g. 30% of maximum possible torque) indicates that all
(or substantially all) solids have been evacuated from
the centrifuge. It is desirable to have the centrifuge
cleaned out of solids prior to stopping because this
avoids plugging of the centrifuge.
To insure that the bowl and conveyor are rotating at
a desired speed before the feed pump is activated, a sub-
method is done as in Fig. 29A. To begin ("START") the
system is queried to see if the bowl and conveyor
rotation speeds are equal to or greater than the
acceptable minimum speeds ("IS BOWL RPM MINIMUM SPEED";
"IS CONVEYOR RPM MINIMUM SPEED"). If so, and if there are
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no system faults ("ARE THERE ANY SYSTEM FAULTS?"), and if
the conveyor torque is less than or equal to 90% of the
full torque (a pre-set maximum, e.g. in pound-feet) ("IS
CONVEYOR TORQUE < 90%"), then the feed pump is activated
("FEED PUMP ACTIVATED") and this submethod is done
("FINISH").
The feed pump is disabled ("FEED PUMP DISABLED") if
there are faults (e.g. VFD faults in the bowl VFD or the
conveyor VFD, etc.) in the system or if the conveyor
torque is at a high level.
Fig. 29B illustrates a torque protection method
according to the present invention implemented by the
control system, e.g. by a computer programmed to execute
steps as listed, so that a desired maximum torque is not
exceeded. A full maximum torque for the conveyor motor is
preset in the control system. If ("YES") the actual
torque is greater than or equal to 90% of this pre-set
maximum for 1.5 seconds or more, ("CONVEYOR TORQUE 90%?
(1.5 SECONDS OR MORE)), the control system shuts down the
feed system's pump ("SHUT DOWN FEED PUMP"; "FINISH"). If
the torque is not greater than or equal to 90% of the
pre-set maximum for 1.5 seconds or more ("NO"), and the
torque is ("YES") greater than or equal to a preselected
percentage (e.g. 80%) of the pre-set maximum for 3
seconds or more ("CONVEYOR TORQUE 80%? (3
SECONDS OR
MORE)), the feed pump motor is slowed down (to avoid
centrifuge plugging), e.g. to a pre-set percentage of a
preselected maximum feed pump speed, e.g. 20% to 60%, or
e.g. by 50% ("FEED PUMP RPM = FEED PUMP RPM/2" "FINISH").
With the sub-method of Fig. 29B constantly
operational, if the conveyor torque reads above a certain
level (e.g. 80% of pre-set maximum) for a certain time
period (e.g. 3 seconds), the feed pump output is reduced
(e.g. by 50%); or if the conveyor torque reaches a higher
level (e.g. 90% of the pre-set maximum) for a pre-set
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time period (e.g. 1-5 seconds), the feed pump is turned
off. If the bowl torque is greater than or equal to 95%
of a pre-set maximum for a time period T, the pump also
slows down. If the bowl torque or the conveyor torque
equals 100% of the pre-set maximum, the system shuts
down; and if the pump torque equals 100% of the pre-set
maximum, the pump (only) shuts down.
Fig. 29C illustrates a system shut down method
according to the present invention implemented by the
control system, e.g. by a computer programmed to execute
steps as listed. If there is any fault sensed for the
bowl VFD, the conveyor VFD ("CONVEYOR OR BOWL VFD FAULT")
or for the pump VFD ("PUMP VFD FAULT"), the system is
shut down ("FINISH"). In the event ("YES") of a pump VFD
fault, the pump is shut down ("STOP PUMP") and the
centrifuge continues running. In the event of a bowl VFD
or conveyor VFD fault ("YES"), the centrifuge is stopped
("STOP ALL CENTRIFUGE OPERATIONS"). If there is a fault
in a conveyor or a bowl VFD, a signal is sent to the two
non-faulty VFDs, insuring that a touch screen reset
button will be pressed before restarting the centrifuge.
If there is a conveyor or bowl VFD fault, centrifuge
operations cease ("STOP ALL CENTRIFUGE OPERATIONS") and,
until restart, this sub-method is done ("FINISH").
Figs. 30A - 43 illustrate touch screen apparatus
displays of a control system according to the present
invention.
Fig. 30A presents an initial screen for selecting a
language for communication between an operator and the
control system. The computer (or computers) of the touch
screen apparatus and/or of the control system can be
programmed to use any known language (e.g., but not
limited to, French, Arabic, Russian, Spanish, English,
Urdu, Italian, German, Hindi, Chinese, Japanese) which
has a written alphabet, pictogram, Portuguese or symbol
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system.
Fig. 30B illustrates the system querying a user for
a password so that the user can access restricted parts
of the system.
Fig. 30C illustrates the system time and provides
for selecting a change-time option. Fig. 30D illustrates
a screen used to change the system time.
Fig. 30E illustrates a choice between proceeding
with a new centrifuge and/or new operating parameters
("OK") in which the system will delete the parameters
used for previous operations; or ("GO BACK") will allow
previously used parameters to be operative. The touch
screen of Fig. 30F (which also appears when the system is
first powered on) allows an operator to reset ("RESET")
the system (starting with the screen of Fig. 30A) with
new input parameters or allows the operator to choose to
continue ("CONTINUE") restoring previously-saved
operating parameters.
Fig. 31 presents a Main Menu that includes various
choices:
"Change Operation": leads to subsequent screens regarding
any desired change in system operation, including changes
in equipment, task, operating parameters, and operation
mode.
"Monitor": leads to subsequent screens which provide on-
going real-time displays of actual system operation mode,
task, and parameters.
"Trends": leads to subsequent screens which show
historical system operation data, e.g. previously logged
information regarding torque, RPM's, gallons-per minute
flow, differentials, etc.
"Advanced": a page that allows personnel, e.g.
supervisors and engineers, to monitor additional
functions and features of the VFD's and of the
centrifuge, e.g. leading to the touch screen of Fig. 33B
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(and proceeding to this screen can be password
protected).
"Maintenance": leads to subsequent screens which display
items and parts monitored for regular maintenance and
times and time periods for maintenance, and, in certain
aspects, whether any maintenance alarm is active.
"Clean": provides an option of rotating the conveyor to
clean the centrifuge of solids that are stuck which can
cause high torque.
"Mud Prop": leads to a touch screen as in Fig. 31G which
allows entry of (and then reference to) the properties of
the particular drilling fluid ("mud") being processed and
the amount of solids in the incoming mud ("% Solids
Content In") and in the outgoing mud ("% Solids Content
Out") as well as the other parameters indicated in Fig.
31G.
As shown in Fig. 31, the system can be programmed so
that the screen portrayed in Fig. 31 (and any and every
screen at any point in system operation) can display
whether or not there is any active alarm. The alarm
indicator may blink on and off and may be accompanied by
additional system sight and/or sound alarm indicators
(e.g., but not limited to, sirens, horns, blinking
lights, etc.). Active alarms can include, among other
things, an alarm for any maintenance that needs to be
done.
Fig. 31A illustrates operator selection of a
particular centrifuge system to be controlled. Fig. 31B
illustrates specific known centrifuges whose information
and operational parameters are stored in memory of the
touch screen apparatus and/or in memory of some other
media of the control system and/or in a removable memory
device usable with the touch screen apparatus, the
control system apart from the touch screen apparatus, or
both.
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Fig. 31C illustrates selection of a particular type
of pump present in a particular centrifuge system, e.g. a
PDP pump or a centrifugal pump (or selection of a flow
meter). Fig. 31D illustrates specific pumps whose
information and operational parameters are in the system
(in any memory described above). The pump option will be
bypassed if a flow meter is connected to the system.
Fig. 31E is a confirmation page regarding system
activities made in previous selections and illustrates
selection of various operational tasks and of operation
in an idle mode. If idle mode is selected (Fig. 31E), the
touch screen of Fig. 31F is displayed. If "YES" is
selected, an operations screen (e.g. like that of Fig.
36A) is displayed. Fig. 31F queries the operator to
insure that this selection is desired. In idle mode the
bowl runs, e.g. at 600 rpm or less; the conveyor motor
runs at 400 rpm or less; the conveyor motor runs in
reverse and the pump is off. In certain aspects, the
system is run in idle mode to preserve a wall cake on the
centrifuge or to keep the centrifuge idling in a cold
environment. Neither the bowl motor nor the conveyor
motor is OFF in idle mode. When the operator activates
the "YES" button of Fig. 31F, idling occurs almost
instantaneously (i.e., on-the-fly).
Fig. 32 illustrates optional selection of one of two
methods for controlling G-force on the bowl of the
centrifuge system . The "RPM METHOD" is a known method
used for many years to control the G-force. It does so by
controlling (e.g. by adjusting) the speed of the bowl and
the speed of the conveyor - by controlling the speed of
the bowl motor and the speed of the conveyor motor.
The other control method which can be chosen is the
G-force differential control method (see discussion below
regarding these control methods regarding Figs. 36A -
36D).
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Fig. 33A is a screen which has the operator confirm
various selections, e.g., centrifuge (specific), function
(e.g. Dewatering/Clarification Mode), Pump (type,
"Centrifugal"), starting bowl speed, starting conveyor
speed, starting G-force differential, starting speed
differential, maximum speed differential, and maximum G-
force. If the operator wants to change something, "BACK"
is chosen.
Fig. 33B illustrates various system devices and
parts, states and parameters.
Fig. 34 illustrates various system parameters whose
historical values and whose present value can be
displayed, e.g. in graphical form on screen.
Fig. 35 illustrates the display of real-time live
data for the speed of the conveyor and of the bowl
(pushing PLOT HOME returns an operator to the screen of
Fig. 34.
Fig. 36A is a screen display illustrating various
system modes and parameters. The operator can choose to
reset the system VFD's; adjust the G-force; adjust the
speed differential; or adjust the rate of feed of the
feed pump. The operator can start the centrifuge system;
view the speed control, "RPM CONTROL", and change the
speeds; or go to the system Main Menu. This screen also
displays the specific centrifuge system being controlled
and the chosen operational task. The "RPM CONTROL" button
is for changing between the two different control methods
- G-force differential control and RPM control.
Fig. 36B illustrates the operator having chosen
"Adjust G Force" and the screen buttons which provide for
the adjustment up or down with the current G-force (e.g.
"93 G's") displayed.
Fig. 36C illustrates the operator having chosen
"Adjust Differential" and the screen buttons which
provide for the adjustment of the speed differential
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(with the current differential, e.g. "17.54 RPM").
Fig. 36D illustrates the operator having chosen
"Adjust Feed Pump" and the screen buttons which provide
for adjusting the speed of the feed pump motor. This
screen also permits stopping and starting of the feed
pump with pre-set parameters. For a centrifugal pump
only, pushing START renders operative a pre-set pump
speed (e.g. as displayed on the screen of Fig. 33B).
Pushing STOP stops the pump. Pushing HIDE hides the
"Pump" sub-panel.
Fig. 36E is an operations page for controlling the
system in the RPM method mode and illustrates a screen
which provides for change of direction of the system's
conveyor motor. The "G Control" button illustrates that
an operator can switch, on-the-fly, from the RPM method
to the G-force method (e.g. to a touch screen as in Fig.
36A). Via the screen of Fig. 32, the G-force mode can be
initially selected (shown in Fig. 36A).
Fig. 37 illustrates the centrifuge system in idle
mode with the pump off. An operator can get to this
screen via the touch screen of Fig. 31E. If the operator
presses RESET on the screen of Fig. 37, the touch screen
of Fig. 37A is displayed. Via the screen of Fig. 37A an
operator can reset all VFD's; reset the pump VFD' or go
back to a previous operations page. In the operation
state shown in Fig. 37, the system is operating to avoid
plugging of the centrifuge. If the operator pushes RESET,
Fig. 37, the screen of Fig. 37A is displayed. If the
operator pushes START, the centrifuge is started (e.g.
with the bowl at 600 RPM and the conveyor motor at 400
RPM to preserve the wall cake) ("The purpose of this page
is to preserve the wall cake when the centrifuge is not
running").
Fig. 38 illustrates the option to clean the
centrifuge by controlling the conveyor motor in either
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direction ("Clean Forward" or "Clean Reverse").
Fig. 39 illustrates a maintenance program and
maintenance status for various parts and items of the
controlled centrifuge system. "Service" is pushed by an
operator to indicate that the task has been done. Pushing
"Later" will provide a future alert to the operator (e.g.
within a pre-set number of hours).
Fig. 40 illustrates a method for shutting down the
centrifuge system. It instructs the operator to first
shut down the feed pump by pressing "STOP PUMP." It
instructs the operator to wait until both bowl torque and
conveyor torque are below a percentage of a pre-set
maximum, e.g. below 40%. The real time torques are
displayed as "BOWL TORQUE" and "CONVEYOR TORQUE." Then,
once the torque parameters are satisfied, the operator
presses "STOP CENTRIFUGE."
Fig. 41 illustrates a screen indicator that the pump
is off, "PUMP SPEED 0 RPM," and that it is safe to stop
the centrifuge.
Fig. 42 illustrates the status of on-going alarms,
if any.
Fig. 43 illustrates that the touch screen apparatus
either is no longer in communication with the centrifuge
system due to operator choice or that, for some reason,
(e.g. cable disconnection or breakdown) the connection
with the centrifuge system has been lost or disabled.
For any individual step of any method according to
the present invention disclosed herein, any steps of any
such methods, and for any method according to the present
invention, the step, steps and/or method are computer-
based and/or computer implemented step, steps, and/or
method via at least one programmed computer, e.g., but
not limited to a touch screen apparatus computer or a
control system computer. Each such step, steps, and/or
method includes a corresponding computer program product
CA 02732663 2011-02-01
WO 2010/023489 PCT/GB2009/051096
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embodied on a computer readable medium and/or a computer-
readable storage medium on which is recorded a program
for a computer to execute said step, steps and/or method
and/or a computer readable mediumõ containing
instructions that, when executed by a computer, implement
said step, steps, and/or method.
